Boltless support and securement of solar modules

ABSTRACT

Systems and techniques for boltlessly supporting and securing solar modules are disclosed. For example, in an aspect, a system features a support structure including a support rail, and a frame including a plurality of rails each having a slot to receive a solar module therein and a bottom plate to boltlessly couple to the top surface of the support rail via one or more boltless mounting components. A boltless mounting component may include a post operative to interlock with an insertion hole for securing the frame to the support structure. Moreover, a locking pin may be disposed through a pin hole on each of the top surface of the support rail and the bottom plate of the frame, where the locking pin advantageously maintains a predetermined alignment and advantageously provides a shared electrical ground connection between the support rail and the frame.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Patent Application Ser. No. 15/929,651 filed on May 14, 2020, which claims the benefit of priorities of U.S. Provisional Application No. 62/847,759 filed May 14, 2019, and U.S. Provisional Application No. 62/878,474 filed Jul. 25, 2019, the contents of which are herein incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION

The present invention relates to a method and apparatus for module attachment to a support structure and, more particularly, to boltless module attachment.

Solar panels or modules are mounted to support structures designed to hold the panel in place in an orientation facing the sun or about 20° from horizontal. Current module attachment typically utilizes 4 manually inserted bolts per module. A typical solar field may have about 20 to ≥680,000 solar panels. Therefore, many thousands of bolts, even millions in some cases, must be used to install a solar field.

The bolts are difficult to position. One person holds the panel in place while another person inserts a bolt from the back of the panel, leading to awkward ergonomics for the installer team. Maintaining alignment during this assembly process is time consuming and difficult due to the height of the work, the weight of the modules, and the angle of installation. In cold weather, the bolt placement and assembly are even more difficult due to the need to wear gloves. Many bolts are lost in this process and assembly requires a lot of time. Missing bolts may result in module damage after system commissioning.

Moreover, the bolts require initial torquing as well as recurring torquing over the 20+ year life of the system. The bolts may need to be retorqued each year or after each major weather event, leading to additional installation and maintenance expense. It is impossible to determine whether the bolts have been properly torqued after assembly without untightening and retorqueing. Moreover, inspectors are required to visually mark each connector as it is torqued or may mark connectors without assurance that torquing has been properly performed.

The bolts are secured with nuts and specialized washers that often feature ribs to provide electrical grounding between the module frame and the support structure. When nuts are missing or under-torqued, additional grounding screws, wires, cables, or straps must be added to assure electrical ground continuity between the solar module frame and support structure. Otherwise, the solar array may not be properly grounded, leading to potential safety and performance risks.

As can be seen, there is a need for an optimized and lower cost system, method, and apparatus for attaching a module to an underlying support structure without the use of bolts.

The present invention provides a new panel attachment system and method therefor using interlocking flanges and/or interlocking stud and slot components. The “perfect alignment and rapid torquing” (PART™ ) system eliminates the need for bolts when attaching solar panels to support structures, which speeds assembly even with gloves. The inventive panel frame may comprise a slot. The support structure may comprise a stud. The installer may position the panel slot(s) over the stud(s) and drop the panel into the slot. Alternatively, the panel frame and support structure may have interlocking flanges. No bolts and no torquing are required.

The invention provides lower costs, faster installation, and may reduce defects introduced using traditional installation methods.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a boltless module mounting system, comprising at least one module frame having a module therein; at least one support structure having support rails; and plurality of boltless mounting components operative to attach the at least one module frame to the support rails.

In another aspect of the present invention, a boltless module mounting system is provided, comprising at least one module comprising posts and at least one support structure comprising support rails with receiving slots having a receiving hole and two or more slide slots, wherein said posts are operative to interlock with said receiving slots.

In another aspect of the present invention, a method of installing a boltless module is provided. The method comprises providing a boltless module frame with a module therein, said boltless module frame further comprising a plurality of boltless connectors, providing a support structure with a plurality of boltless connectors, aligning the plurality of boltless connectors, lowering said boltless module frame onto said support structure, and sliding said boltless module frame such that the plurality of boltless connectors interlock.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a detail perspective view of a boltless module and frame according to an embodiment of the invention;

FIG. 2 is a detail perspective view thereof, with the glass and solar cell laminate of the module hidden for clarity;

FIGS. 3, 4, and 5 are perspective views illustrating installation thereof;

FIG. 6 is a sectional view thereof, taken along line 6-6 in FIG. 2;

FIG. 7 is a detail perspective view of a boltless module mounting system according to another embodiment of the invention;

FIG. 8 is a detail exploded view thereof;

FIG. 9 is a sectional view thereof, taken along line 9-9 in FIG. 7;

FIG. 10 is a detail perspective view of a boltless module mounting system according to another embodiment of the invention;

FIG. 11 is a detail exploded view thereof;

FIG. 12 is a sectional view thereof, taken along line 12-12 in FIG. 10;

FIG. 13 is a perspective view of a boltless module mounting system according to yet another embodiment of the invention;

FIG. 14 is an exploded view thereof; and

FIG. 15 is a sectional view thereof, taken along line 15-15 in FIG. 13.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

As used herein, a solar panel is generally referred to as a “module,” a collection of modules is referred to as a “panel,” a collection of panels is referred to as a “table,” and a collection of tables is referred to as an “array.”

Broadly, one embodiment of the present invention is a boltless module mounting system, comprising interlocking stud and slot components on the module and support structure or interlocking flanges on the module and support structure.

In some embodiments, the inventive solar frame comprises a receiving slot and the inventive support structure comprises a stud corresponding to the frame slot. The stud may be provided on a C or Z rail or a C or Z channel, for example. Alternatively, the frame may be provided with a stud and the support structure may be provided with a receiving slot. In some cases, the stud may be provided directly on the module. In any case, the frame may be held in place by gravitational force, obviating the need for torquing. The receiving slot may be further provided with a notch to further secure the alignment of the frame and support structure and held in place by a cap on the post or rivet. In this method, modules are held in place by gravity during installation and further secured by the post cap/slot alignment when the panels are subject to uplift from prevailing winds

The studs may be fabricated in or on the panel frame or support structure by a manufacturing step selected from the group consisting of stamp, crimp, rivet, swage, and combinations thereof The studs may be manufactured with a cap, head or hat that mechanically prevents the panel frame from separating from the support structure once in position. The receiving slot may be stamped or punched into the frame or the support structure. Preferably, a locking screw, pin or rivet may be provided to prevent the stud from sliding out of the slot due to updrafts from strong winds.

In another embodiment, interlocking flanges may secure the panel frame to the support structure and preserve its alignment. The flanges or tabs may be formed in or on the panel frames and support structure rails by a method selected from the group consisting of stamp, weld, swage, screw, glue, and combinations thereof. The flange may also be described as a frame lip, a frame edge, or rail.

Module support structures are generally manufactured from metal, although the material of manufacture is not particularly limited. In some embodiments, module support structures may feature rivets or slot and stud combinations and structures such as shelving may be assembled using slot and stud components. A stud may also be described as a post, boss, rod, pin, rivet, protuberance, or swage fitting. The studs may be manufactured with a head or hat that mechanically prevents the panel frame from separating from the support structure once in position.

The slot of the present invention may be a type selected from the group consisting of a keyhole slot, a modified keyhole slot with a second slide slot 90° around a receiving hole from a first slide slot, and 180° around the receiving hole from the first slide slot. The dual slide keyhole slot may be particularly useful for structures which may have a slide slot aligned at an angle from the vertical position or for structures that may have a portrait orientation and a landscape orientation. The slot may also be described as a notch, opening, or groove.

In some aspects of the invention, the module frame and/or support structure may be provided with a pin, screw, and/or rivet to provide electrical grounding. A pin, screw, rivet, or rivet pin may additionally provide anti-theft security. Use of pins, screws, and/or rivets assures proper module to support structure grounding without need for additional torquing.

In some aspects of the invention, one or more studs may be hollow and may be provided with a rivet passing therethrough. The rivet may preferably ground the frame and/or module to the support structure.

In some cases, each module frame may interlock with an adjacent frame, thereby reducing the number of underlying support structure rails required in the system.

Furthermore, the boltless concept may be extended to the entirety of the support structure, thereby reducing the number of required bolts for the assembly.

None of the embodiments of the invention preclude the use of bolts in addition to the slot and stud or interlocking flange connections.

Referring to FIGS. 1-15, FIGS. 1-6 illustrate a module 36 according to an embodiment of the invention with a module frame comprising rails 10 with rail bottom plates 14 and panel slots 22 to hold the module's glass/solar cell laminate 36. The rail bottom plates 14 may have a plurality of modified keyhole slots, each having an insertion hole 16 and two locking slots 18 perpendicular to each other. The rail bottom plates 14 may also have a plurality of ground pin holes 20. The frame may be installed onto a support structure as shown in FIGS. 3-5. The module frame may be lowered onto the support rail 24 with insertion holes 16 aligned over studs or posts 28 and slid into position so that posts 28 rest in locking slots 18. The frame may be further secured using rivets 32 through the posts 28, such that a rivet compression portion 34 remains beneath the post retainer 30. With the support rail 24 ground pin holes 26 aligned with the bottom plate 14 ground pin holes 20, a locking pin, screw or self-tapping screw may be used to lock the frames into position, maintaining alignment, and to provide an electrical ground connection between the metal parts.

FIGS. 7-9 illustrate an alternate embodiment in which the locking slots 40 extend in opposite directions from the insertion hole 38. The module frame may be slid into position such that the post 42 rests in a locking slot 40.

FIGS. 10-12 illustrate another embodiment in which the bottom plate 14 has a rail slot 44 with a rail flange or rail tab 46 extending beneath and parallel to the rail slot 44 and the support rail 24 has a support slot 48 with a support flange or support tab 50 extending above and parallel to the support slot 48. The bottom plate 14 may be installed onto the support rail 24 by lowering the bottom plate 14 onto the support rail 24 with the rail slot 44 and the support slot 48 aligned such that the rail tab 46 extends into the support slot 48 and the support tab 50 extends into the rail slot 44 and sliding the module frame into position such that the rail tab 46 couples with the support tab 50.

In some embodiments, a frame rail 10 and a reverse frame rail 52 may be installed together on the same support rail 24, as shown in FIGS. 13-15, reducing the support structure necessary and providing further savings. The reverse rail insertion hole 56 in the reverse rail bottom plate 54 may be aligned with the insertion hole 38 in the bottom plate 14 so that the grounding pin holes 20, 60 are aligned, the rails 10, 52 are back to back, and the panel slots 22, 62 extend in opposite directions. The paired rails 10, 52 may be lowered onto a support rail with the insertion holes 38, 56 aligned with an extended support rail post 64 and the module frame may be slid into position so that the post 64 rests within locking slots 40, 58.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A boltless system for supporting and securing a solar module, the system comprising: a support structure including a support rail having a top surface; a frame including a plurality of rails, each of the plurality of rails having (a) a slot at a first end thereof and (b) a bottom plate at a second end thereof, wherein the slot is structurally configured to receive at least a portion of a solar module therein, and wherein the bottom plate is structurally configured for coupling to the top surface of the support rail; one or more boltless mounting components operative to attach the frame to the support rail, at least one of the one or more boltless mounting components including (i) a post integrated onto at least one of the top surface of the support rail and the bottom plate of the frame, and (ii) an insertion hole on at least one of the top surface of the support rail and the bottom plate of the frame, wherein the post is operative to interlock with the insertion hole for securing the frame to the support structure; a pin hole disposed on each of the top surface of the support rail and the bottom plate of the frame, wherein a predetermined alignment of the support rail and the frame is maintained when the pin hole of the support rail is aligned with the pin hole of the frame; and a locking pin disposed through the pin hole of each of the top surface of the support rail and the bottom plate of the frame, the locking pin maintaining the predetermined alignment and providing an electrical ground connection between the support rail and the frame.
 2. The system of claim 1, wherein the post defines a void for receiving at least a portion of a rivet therethrough, the rivet including a portion that is compressible to secure a position of the post relative to the insertion hole.
 3. The system of claim 1, wherein the locking pin includes a rivet.
 4. The system of claim 1, wherein the locking pin includes a self-tapping screw.
 5. The system of claim 1, wherein at least one of the boltless mounting components comprises (i) a tab integrated onto at least one of the top surface of the support rail and the bottom plate of the frame, and (ii) a slot on at least one of the top surface of the support rail and the bottom plate of the frame, wherein the tab is operative to interlock with the slot for securing the frame to the support structure.
 6. The system of claim 1, wherein the insertion hole comprises a modified keyhole formation with at least one locking slot extending from a receiving hole.
 7. The system of claim 6, wherein the modified keyhole formation includes at least two locking slots.
 8. The system of claim 1, wherein the post is integrated onto the top surface of the support rail, and wherein the insertion hole is disposed on the bottom plate of the frame.
 9. The system of claim 1, wherein the post is integrated onto the bottom plate of the frame, and wherein the insertion hole is disposed on the top surface of the support rail.
 10. The system of claim 1, wherein the plurality of rails of the frame include at least a first module frame rail and a second module frame rail, wherein slots of the first module frame rail and the second module frame rail oppose one another when bottom plates of the first module frame rail and the second module frame rail are stacked upon one another.
 11. The system of claim 1, wherein the post includes one of a cap, a head, or a hat that mechanically prevents the frame from separating with the support structure when in the predetermined alignment.
 12. A method of supporting and securing a solar module, the method comprising: placing a bottom plate of a frame on a top surface of a support rail of a support structure, the frame including a rail having a slot structurally configured to receive at least a portion of a solar module therein; engaging, without using bolts, one or more boltless mounting components to attach the frame to the support rail, at least one of the one or more boltless mounting components including (i) a post integrated onto at least one of the top surface of the support rail and the bottom plate of the frame, and (ii) an insertion hole on at least one of the top surface of the support rail and the bottom plate of the frame; interlocking the post with the insertion hole to at least partially secure the frame to the support structure; aligning a pin hole on the top surface of the support rail with a pin hole on the bottom plate of the frame to place the support rail and the frame in a predetermined alignment; and securing a locking pin through the pin hole of each of the top surface of the support rail and the bottom plate of the frame thereby maintaining the predetermined alignment and providing an electrical ground connection between the support rail and the frame.
 13. The method of claim 12, further comprising placing at least a portion of a rivet within a void of the post, and compressing a portion of the rivet to secure a position of the post relative to the insertion hole.
 14. The method of claim 12, wherein the locking pin is a rivet.
 15. The method of claim 12, wherein the locking pin is a self-tapping screw.
 16. The method of claim 12, wherein at least one of the boltless mounting components comprises (i) a tab integrated onto at least one of the top surface of the support rail and the bottom plate of the frame, and (ii) a slot on at least one of the top surface of the support rail and the bottom plate of the frame, wherein the tab is operative to interlock with the slot for securing the frame to the support structure.
 17. The method of claim 12, wherein the post is integrated onto the top surface of the support rail, and wherein the insertion hole is disposed on the bottom plate of the frame.
 18. The method of claim 12, wherein the post is integrated onto the bottom plate of the frame, and wherein the insertion hole is disposed on the top surface of the support rail.
 19. The method of claim 12, further comprising forming at least a portion of the frame by stacking a bottom plate of a first module frame upon a bottom plate of a second module frame such that a panel slot of the first module frame opposes a panel slot of the second module frame.
 20. The method of claim 12, further comprising placing at least the portion of the solar module within the slot. 